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7/28/2019 Robotics Welding Brochure
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RoboticWelding
Solutions
7/28/2019 Robotics Welding Brochure
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Why Automation? Why Miller? Simple Solutions with Pre-Engineered Performance
Businesses of all sizes can benet from automation.
Companies with as few as two employees have
purchased Miller robotic welding automation equipment
and experienced great success on many levels,
including performance, payback and new technology
applications.
We have developed a family of pre-engineered solu
integrating Panasonic robots, servo positioners an
welding technology to solve your fabrication challen
This seamless integration makes learning the proc
easier, allowing you to concentrate on other areas
business.
Workforce transitions
the workforce shifts from manual labor to highly
chnological jobs, Miller offers a solution that addresses
e shortage of skilled welders robotic automation.
though the prospect of automation can be intimidating,
mpanies large and small are turning to robotic welding
cause it:
Increases productivity
Prevents over-welding
Improves rst-pass weld quality
Produces less scrap and rework
Complies with safety regulations
Lowers the cost of doing business
our trusted welding partner
ller provides unparalleled customer
pport and partners with weldingstributors to improve your business and
ovide solutions for the toughest welding
allenges. As your guide every step of the
ay, we can evaluate all the automation
tions available to you, then recommend
e robot system and integration partner
at ts your needs. We can also provide
grade options and explain their costs versus benets.
Your one-stop resource
r Automate with just a single point of contact a Miller
welding professional can guide you through every step
of the automation process.
rWork with partners you know and trust your Miller
representative and local welding distributor.
r Choose from among the industrys best automation
system integrators and robot suppliers.
r Benet from real system intelligence and partnership
that delivers all the performance you need.
7/28/2019 Robotics Welding Brochure
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Unlimited Applications
A and TB Series robotse latest generation of robotic manipulators incorporates
D design and nite element analysis (FEA) to optimize
idity and speed in the TA and TB Series robotic lines.
rger motors and drives, together with high-end servo
ntrol algorithms, make the TA Series more than 50
rcent faster than our previous generation of robots
hile the TB Series features a through-arm design for
ht-access applications. With unlimited exibility, these
botic manipulators are ready to work in your toughest
plications.
Advanced sensitivity When servo control algorithms
detect undue load on the robot during motion, they
drop servo power to a soft state to protect the robot
from collisions.
Less interference A curved arm design, offset wrist
and slim prole reduce robot self-interference, allowing
for larger overall working ranges.
Safety compliance The most rigorous safety
standards ensure your investment is not only
productive, but safe for your employees (RIA, UL and
c-UL compliant).
r Easy to operate Each teach pendant runs MicrosoftWindows CE with a 7-inch color thin lm transistor (TFT)
display and uses common computer commands, which
makes learning the process easier.
r Adaptive ll When combined with Multi-Pass
software and Root Pass Memorization, the robot can
repeat a weld pattern while adapting to the changing
part. The specialized programming menus on the robot
are designed specically for this process. The visual
macros and graphical prompts make this software easy
to understand and easy to use.
The robot can weld real-world parts with variation. Your
quality goes up and your teaching time goes down.
Adaptive ll senses the edges of the weld joint as the
robot weaves back and forth. The robot then adjusts
the amplitude of the weave points based on the arc
sensing at the weaving edges. The robot will adjust
welding travel speed based upon the changing weaving
amplitude and the feedback from the welding arc, giving
a consistent ll, even though the joint dimensions are
changing.
TA-1000G2/WGMax reach: 1068 mm
6 kg (13 lb.) payload
TA-1600G2/WGMax reach: 1598 mm
8 kg (17.6 lb.) payload
TA-1900G2/WGMax reach: 1895 mm
6 kg (13 lb.) payload
TA-1400G2/WMax reach: 1374 m
6 kg (13 lb.) payload
TA-1800G2/WMax reach: 1796 m
8 kg (17.6 lb.) paylo
Reach and Capacity for Any Application
TA CONTROLLER
TEACH PENDANT
TB-1400G2/WMax reach: 1437 mm
4 kg (8.8 lb.) payload
TB-1800G2/WMax reach: 1802 mm
4 kg (8.8 lb.) payload
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Technical Innovation
Continuous evolution with MIG
TAWERS aluminum MIG
r Aluminum package can be retrotted to any existing
TAWERS robot.
r Servo wire feed system is ultra-stable.
r Lift-start function improves arc starting.
r
Low-pulse function allows for oscillation between twoparameters (highlow) during welding, producing the
Prole Pulse stacked dime weld bead appearance
without back-stepping.
r Synchro-weave function provides true synchronous and
instantaneous control of wire feed, parameter control and
robot motion while weaving between plates of unequal
thicknesses.
Continuous evolution with TIG
TAWERS high deposition TIG
r TIG package can be retrotted to any existing
TAWERS robot.
r Touch-start function eliminates high-frequency noi
during arc starts.
r Unique ller wire arrangement reduces
feeding-related issues.
r
Wire can enter puddle from any position.r Current shunt function preheats ller metal to imp
wire deposition.
r Embedded arc control function provides true
synchronous control of wire feed, parameter contr
robot motion. Prole Pulsestacked dime weld b
appearance without back-stepping is easily achiev
r Torch design is compact.
r Arc voltage height-control function is optional.
Using Embedded Arc Control Technology (EAC)
AC technology creates newpportunities
WERS comes standard with EAC technology, which
minates the need for three control systems by
mbining the robot, welder and servo wire feeder
ntrols into a single unit. Contained inside the robot
ntroller, this new system is monitored by the TAWERS
4-bit main CPU.
AC technology controls the robot motion path, and
nchronizes the welding power supply and servo wire
eder to adjust for dynamic changes in the welding
ocess. TAWERS soars beyond conventional digital
mmunication systems, delivering the rst generation of
ly software-controlled robotic welding solutions.
Robot lift start When the robot senses current ow
during the arc start process, it creates the arc using
voltage not current to dramatically limit ignition
spatter and increase rst arc strike efciency.
r Robot lift end The robot lifts to end the weld
cratering process, eliminating wire-stick detection and
burnback times, while simultaneously sharpening the
welding wire.
r Optional embedded arc data monitoring By
screening variables and data for quality control, you
can nd root causes to problems that could result in a
suspect part reaching the end customer.
7/28/2019 Robotics Welding Brochure
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External Welding Power Supplies
GBII-350
r Spatter-controlled High-end waveform algorithms
control welding spatter during the MIG (CV) process,
minimizing the ball size and adhesion of the spatter and
increasing the deposition efciency, especially when
welding with 100% CO2.
r Fully digital Digital communication is possible via
a connection to any Panasonic robot system PC tools
(RSPCT) robot controller with plug-and-play capability and
full waveform control from the teach pendant.
r Capable of low-voltage and thin-gauge welding The
optimized waveform control allows stable arc control at
low voltages for excellent thin-gauge welding.
Auto-Axcess E with Insight
r Defect detection Auto-Axcess E with Insight
data monitoring can detect when welding feedb
outside its predetermined limits. On a weld-by-w
basis, Insight can monitor current, voltage, wire
speed, gas ow and duration to ensure that all
are applied according to specications and i
shut down the system when critical faults occur
r Management information Insight Reporter
welding process improvement using productivity
totalization and quality information, including ro
cell state, arc time, parts produced, welds prod
wire used, gas used, downtime and overall equ
effectiveness (OEE).
r Ethernet Using the Auto-Axcess E custom da
you can monitor as many as 10 critical system
attributes at one time from virtually anywhere in
world. You can even change system conguratio
settings and update rmware via Ethernet conn
HMII-350/HMII-500
r Flexible Three interactive Pulse control
modes (soft, hard, hybrid) accommodate various
applications and help cover gaps, reduce spatter
and customize the arc to your specications.
r Quick and clean Two starting modes (MIG [CV]
and Pulse) use a patented two-step high current
impulse routine for virtually instantaneous spatter-
free arc starts.
r High quality Patented dip Pulse technology clears
shorts caused by puddle interference, minimizing
spatter adhesion in a real-time routine to provide
higher travel speeds and improved welding quality.
r Fully digital Digital communication is possible
via a connection to any Panasonic Series robot
controller with plug-and-play capability and full
waveform control from the teach pendant.
External Welding Power Supplies
uto-Axcess systems for roboticutomation
uto-Axcess offers seamless integration of digital control
chnology by combining an inverter welding power
ource with a robotic interface.
A-40GB wire drive motor assembly with over current
otection (OCP) to protect against current surges.
ew design uses an improved sheet metal enclosure
cluding printed circuit board. It features a threaded
as connection and a direct-panel-mounted, quarter-turn
otor control cable connection that eliminates
otion stress on the motors power and tachometer
edback wires.
2-pin HARTING connector for quick, easy connection to
mmon analog robot controllers. DeviceNet connector
r quick, easy connection to common robot controllers
th standard DeviceNet cables.
uto-CAL, a patented automatic calibration feature that
ses the Auto-Axcess internal digital technology to allow
mple, automatic scaling and synchronization to analog
bot controllers. This assures consistent and repeatablesults with minimal downtime when installing
uto-Axcess power sources into existing robot cells.
uto-Line power management technology for any input
ltage hookup (208 575 V) with no manual linking.
ssures rock-solid, consistent output on uctuating
imary lines.
7/28/2019 Robotics Welding Brochure
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Pre-Engineered Performance
rformArc products are built on a core foundation of
nasonic robots, servo positioners and Miller welding
chnology. Designed specically for your fabrication
vironment, each PerformArc product incorporates a
ly welded steel frame and base structure with sheet-
etal-skinned walls. PerformArc offers:
Flexibility PerformArc products are pre-wired and
pre-assembled for fast installation and relocation.
r Central location Full system control, diagnostics,
and programming capabilities in one easy-to-access
location makes learning the process easier and
increases cell uptime.
r Safety features All models include a fully integrated
safety environment with light curtains and door
interlocks.
r Support Your PerformArc system is pre-engineered
and backed by M iller.
A 250 MManually activated turntable
Platen style
250 lb. per side
60 in. table diameter, equally divided
Length 2870 mm (113 in.)
Width 1676 mm (66 in.)
Height 2286 mm (90 in.)
RODUCT DETAILS
pical part sizes (in inches): 12 x 53, 18 x 45, 24 x 30
Fast installation A fully welded frame, shipped to you
pre-wired and pre-assembled, eliminates assembly time
and is up and running in minutes.
Integrated controls An integrated interface and
full-color teach pendant provide full system control,
diagnostics and programming capability in one location,
which makes learning the process easier for the operator.
Productivity and versatility The manually activated
table allows for high output-to-investment ratio, which is
ideal for rst-time users and companies with a low volume
of automation projects.
PA 250 M
PA 350 Sr High-speed servo turntable
r Platen style
r 350 lb. per side
r 60 in. table diameter, equally divided
r Length 3988 mm (157 in.)
Width 1727 mm (68 in.)
Height 2286 mm (90 in.)
PRODUCT DETAILS
Typical part sizes (in inches): 12 x 53, 18 x 45, 24 x 30
r Fast installation A fully welded frame, shipped to you
pre-wired and pre-assembled, eliminates assembly time
and is up and running in minutes.
r Repeatability A standard platen design with bolt and
dowel holes allows multiple xtures to be exchanged on
the same work cell.
r Productivity The Panasonic AC servo positioner turns
180 in under 2.2 seconds, minimizing index time and
maximizing productivity.
PA 350 S
A Full Range of Products
PA 750 Sr High-speed servo turntable
r Platen style
r 750 lb. per side
r 92 in. table diameter
r Length 4724 mm (186 in.)
Width 2489 mm (98 in.)
Height 2286 mm (90 in.)
PRODUCT DETAILS
Typical part sizes (in inches): 12 x 87, 24 x 76, 36 x 53
PA 750 SWr High-speed servo turntable
r Platen style
r 750 lb. per side
r 107 in. table diameter
r Length 5131 mm (202 in.)
Width 2896 mm (114 in.)
Height 2286 mm (90 in.)
PRODUCT DETAILS
Typical part sizes (in inches): 12 x 104.5, 24 x 95, 36 x 77,
48 x 43
r Fast installation A fully welded frame, shipped to you pre-
wired and pre-assembled, eliminates assembly time and is up
and running in minutes.
r Repeatability A standard platen design with bolt and dowel
holes allows multiple xtures to be exchanged on the same
work cell.
r Flexibility A large work area and 725 pound-per-side
payload accepts larger parts, nest-type processing of smaller
parts and progressive xtures.
PA 550 Hr High-speed servo turntable
r H-frame style
r Two outboard servo positioners
r 550 lb. per side
r 48 in. between face plates, 34 in. turning diam
r Length 4724 mm (186 in.)
Width 2489 mm (98 in.)
Height 2286 mm (90 in.)
PRODUCT DETAILS
Maximum part size (in inches): 34 x 48
PA 550 HWr High-speed servo turntable
r H-frame style
r Two outboard servo positioners
r 550 lb. per side
r 60 in. between face plates, 40 in. turning diam
r Length 5131 mm (202 in.)
Width 2896 mm (114 in.)
Height 2286 mm (90 in.)
PRODUCT DETAILS
Maximum part size (in inches): 39.37 x 60
r Fast installation A fully welded frame, shipped to
wired and pre-assembled, eliminates assembly time
and running in minutes.
r Maximum accessibility Outboard servo positione
for easy loading or load-and-tack operations while m
torch accessibility.
r Safety Outboard axis power is disconnected duri
xture loading to prevent unexpected motion while t
maintains production.
PA 750 S PA 550 H
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PA 1100 SS*r Two opposing welding stations
r Independent style
r Two outboard servo positioners
r 1100 lb. per side
r 120 in. between faceplates, 44 in. turning diameter
r Width 4987 mm (196 in.)
Depth 4254 mm (167.5 in.)
Height 2286 mm (90 in.)
PA 2200 SS*r Two opposing welding stations
r Independent style
r Two outboard servo positioners
r 2200 lb. per side
r 120 in. between faceplates, 60 in. turning diameter
r Width 5357 mm (211 in.)
Depth 4991 mm (196.5 in.)
Height 2286 mm (90 in.)
PRODUCT DETAILS
Maximum part size (in inches): 60 x 120
Optional sizes (in inches): 66 x 120, 66 x 44
r Open design The sidewall design allows for heavier
weldments to be crane-loaded, while standard load station jog
allows unlimited positioning for multi-side part loading ofnal
weldout.
r Maximum accessibility Outboard servo positioners allow
for easy loading or load-and-tack operations while maximizing
torch accessibility.
r Safety Outboard axis power is disconnected during
xture loading to prevent unexpected motion while the robot
maintains production.
PA 1100 SS
RJC71
RJB31
RJB1121
RJR41
RJR51
Our servo-controlled positioners are designed for precision
welding on round tubes and pipes. Simply clamp each end of the
material to a positioner for 360 degrees of access.
r Built-in safety All Panasonic servo positioners come
standard with servo disconnect technology and a host of
software commands that allow exibility while maintaining
operator safety.
r Versatility These positioners are applicable to MIG,
Pulsed MIG, and TIG welding with built-in rotary ground (500 Acapacity) and through-hole design to pass air and I/O cabling.
r Efciency and ease of use Optional harmonized external
axes control software makes setting welding speeds and
other system parameters easy, reducing the number of taught
points and ensuring the optimum welding position.
r Flexible positioning Panasonic 1000 kg servo positioners
can be used as building blocks in system designs as main
indexers, supplemental outboards, or in combination as
skyhook-style positioners.
A 1100 HWHigh-speed servo turntable
H-frame style
Two outboard servo positioners
1100 lb. per side
60 in. between faceplates
40 in. turning diameter
Length 5309 mm (209 in.)
Width 3085 mm (121.5 in.)
Height 2337 mm (92 in.)
RODUCT DETAILS
aximum part size (in inches): 40 x 60
Production exibility A larger rotation diameter, increased
length, heavier payload and open overhead construction
accommodate larger parts and multiple or progressive
xturing.
Maximum accessibility Outboard servo positioners allow
for easy loading or load-and-tack operations while maximizing
torch accessibility.
Safety Outboard axis power is disconnected during
xture loading to prevent unexpected motion while the robot
maintains production.
PA 1100 HW
PA 2200 SS
* Multi-robot conguration available
Pre-Engineered Performance A Full Range of Products
Servo-Controlled Positioners
PA 1100FW*r High-speed servo sweep
r Ferris wheel style
r Two outboard servo positioners
r 1100 lb. per side
r 120 in. between faceplates, 40 in. turning diameter
r Width 5618 mm (221 in.)
Depth 4567 mm (180 in.)
Height 2286 mm (90 in.)
PRODUCT DETAILS
Maximum part size (in inches): 43 x 118
r High productivity A high-speed Ferris wheel
using three independent servo drives provides ind
leading indexing speed, minimizing cycle-time imp
r Maximum accessibility Outboard servo positioallow for easy loading or load-and-tack operations
maximizing torch accessibility.
r Safety Outboard axis power is disconnected du
xture loading to prevent unexpected motion while
robot maintains production.
PA 1100 FW
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16
As the workforce transitions from manual labor to highly
technological jobs, Miller offers robotic automation to
address the shortage of skilled welders. Our regulation
compliant robotic welding increases productivity and
rst-pass weld quality, reduces over-welding and rework,
offers increased protection and safety for operators and
lowers the cost of doing business. For more information,
visit MillerWelds.com/automation.
Robotic WeldingAutomation
MillerWelds.com/automation# 250707 2011 Miller Electric Mfg. Co. | Miller Welding Automation | 281 E. Lies Rd. | Carol Stream, IL 60188 | 888-843-7693
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